York YPAL 050, YPAL 060, YPAL 051, YPAL 061 User Manual
PACKAGED ROOFTOP
AIR CONDITIONING UNITS
INSTALLATION, OPERATION & MAIN TE NANCE
SIMPLICITY ELITE CONTROL
New Release
YPAL 050
YPAL 051
YPAL 060
YPAL 061
DESIGN LEVEL F
Form 100.50-NOM6 (1207)
035-21979-002
LD13271
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
FORM 100.50-NOM6 (1207)
This equipment is a relatively complicated ap pa ra tus.
Dur ing installation, operation, maintenance or service,
in di vid u als may be exposed to certain com po nents or
conditions in clud ing, but not limited to: re frig er ants,
oils, materials un der pressure, rotating com po nents,
and both high and low voltage. Each of these items
has the po ten tial, if misused or handled im prop er ly, to
cause bodi ly injury or death. It is the obligation and
re spon si bil i ty of operating/service per son nel to iden ti fy
and rec og nize these inherent hazards, protect them selves,
and pro ceed safely in completing their tasks. Failure to
com ply with any of these requirements could re sult in
se ri ous dam age to the equipment and the prop er ty in
which it is sit u at ed, as well as severe personal injury or
death to them selves and people at the site.
This document is intended for use by owner-authorized
operating/service personnel. It is expected that this
in di vid u al possesses independent training that will
en able them to perform their assigned tasks properly
and safe ly. It is essential that, prior to performing any
task on this equipment, this individual will have read
and un der stood this document and any referenced
materials. This in di vid u al will also be familiar with and
comply with all ap pli ca ble governmental standards and
regulations per tain ing to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:
DANGER indicates an im mi nent ly
hazardous situation which, if not
avoid ed, will re sult in death or se ri ous
injury.
CAUTION identifi es a hazard which
could lead to damage to the ma chine,
damage to other equip ment and/or
en vi ron men tal pollution. Usually an
in struc tion will be given, together with
a brief ex pla na tion.
WARNING indicates a potentially
haz ard ous sit u a tion which, if not
avoid ed, could result in death or se-
NOTE is used to highlight ad di tion al
information which may be helpful to
you.
ri ous in ju ry.
External wiring, unless specifi ed as an optional connection in the man u fac tur er’s prod uct
line, is NOT to be connected inside the micro pan el cab i net. De vic es such as re lays, switch es,
transducers and controls may NOT be installed inside the mi cro pan el. NO external wiring
is al lowed to be run through the micro panel. All wir ing must be in ac cor dance with JOHNSON CONTROLS’s pub lished spec i fi ca tions and must be per formed ONLY by qual i fi ed
JOHNSON CONTROLS personnel. JOHNSON CONTROLS will not be re spon si ble for
dam ag es/problems re sult ing from im prop er con nec tions to the con trols or ap pli ca tion of
im prop er con trol sig nals. Failure to fol low this will void the man u fac tur er’s warranty and
cause serious dam age to property or injury to per sons.
2
JOHNSON CONTROLS
CHANGEABILITY OF THIS DOCUMENT
d
P
d
P
FORM 100.50-NOM6 (1207)
In complying with JOHNSON CONTROLS’s policy
for continuous prod uct improvement, the in for ma tion
con tained in this doc u ment is subject to change without
notice. While JOHNSON CONTROLS makes no
com mit ment to update or provide current in for ma tion
au to mat i cal ly to the manual owner, that in for ma tion, if
ap pli ca ble, can be ob tained by con tact ing the nearest
JOHNSON CONTROLS Applied Systems offi ce.
It is the responsibility of operating/service personnel
to verify the ap pli ca bil i ty of these doc u ments to the
equip ment in question. If there is any question in
the mind of operating/service personnel as to the
applicability of these doc u ments, then prior to work ing
on the equip ment, they should verify with the owner
whether the equip ment has been modifi ed and if current
literature is avail able.
NOMENCLATURE
BASE MODEL NUMBER
YPAL050-061
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Base Type Refrigerant Supply
Product Nominal Capacity Application
Y :YORK 5 0 :50 Ton Capacity :208/3/60
P :Packaged Rooftop 0 5 1 :51 Ton Capacity C :R-22 :230/3/60
A :Air Cooled 0 6 0 :60 Ton Capacity E :R-410A 4 6 :460/3/60
L :Scroll 0 6 1 :61 Ton Capacity 5 8 :575/3/60
0 B :R-407C
C :Constant Volume
V :VAV, VFD
F :Flexsys
C :Cooling Only
N :Staged Natural Gas Heat
G :Staged Natural Gas Heat SS HX
M :Full Modulating Gas Heat
F :Full Modulating Gas Heat SS Staged HX
E :Electric Heat
H :Hot Water Heat
S :Steam Heat
Voltage
25
4 0 :380/3/60
4 5 :400/3/50
Openings
B :Bottom Supply
L :Left Supply
R :Right Supply
Return
Openings
B :Bottom Return
R :Rear Return
S :Side Return
Design Special
X :Standar
S :Special
A :Standar
B :Special
F :Revision Level F
LD13270
JOHNSON CONTROLS
3
FORM 100.50-NOM6 (1207)
TABLE OF CONTENTS
BASE MODEL NUMBER ..............................................................................................................................3
CHANGEABILITY OF THIS DOCUMENT .....................................................................................................3
NOMENCLATURE .........................................................................................................................................3
TABLE OF CONTENTS ................................................................................................................................4
LIST OF TABLES ........................................................................................................................................ 11
LIST OF FIGURES ......................................................................................................................................12
SECTION 1 – INTRODUCTION .........................................................................................................13
ECOLOGICAL AND ECONOMICAL DESIGN ............................................................................................13
Condensing Section .............................................................................................................13
Heating Section .....................................................................................................................14
AIR MANAGEMENT ....................................................................................................................................15
CONTROLS .................................................................................................................................................15
INDOOR AIR QUALITY ..............................................................................................................................15
ELECTRICAL ..............................................................................................................................................16
SERVICE AND INSTALLATION ..................................................................................................................16
SECTION 2 – INSTALLATION ...........................................................................................................17
APPROVALS ...............................................................................................................................................17
LIMITATIONS ...............................................................................................................................................17
UNIT INSPECTION ......................................................................................................................................17
LOCATIONS AND CLEARANCES .............................................................................................................17
RIGGING AND HANDLING .........................................................................................................................19
UNIT WEIGHTS ...........................................................................................................................................20
Unit Placement ......................................................................................................................21
Roof Curb Installation ..........................................................................................................22
PHYSICAL DATA .........................................................................................................................................23
GENERAL ARRANGEMENT DRAWING – 050-061 MODELS .................................................................25
Bottom Supply / Bottom Return ..........................................................................................25
Bottom Supply / Side Return ...............................................................................................26
Bottom Supply / Rear Return ...............................................................................................27
Curb Layout Drawing / 050-061 Models ..............................................................................28
ELECTRICAL DATA ....................................................................................................................................29
Electrical Service Sizing ......................................................................................................29
Load Defi nitions: ..................................................................................................................29
FILTERS ......................................................................................................................................................32
CONDENSATE DRAIN ................................................................................................................................32
Condensate Drain Piping .....................................................................................................32
Condensate Drain Trap ........................................................................................................32
AIR HOODS FOR ECONOMIZER ...............................................................................................................33
AIR HOODS FOR FIXED OUTSIDE AIR (UNITS WITHOUT ECONOMIZER) ...........................................33
AIR HOODS FOR EXHAUST AIR ...............................................................................................................33
4
JOHNSON CONTROLS
FORM 100.50-NOM6 (1207)
TABLE OF CONTENTS
FIELD WIRING ............................................................................................................................................33
Thermostat ............................................................................................................................33
Fan input ................................................................................................................................33
Space Sensor ........................................................................................................................33
CO2 Sensor ...........................................................................................................................34
Occupied / Unoccupied Input ..............................................................................................34
Shutdown Input .....................................................................................................................34
Smoke Purge Input ...............................................................................................................34
BAS Economizer Input .........................................................................................................34
Fault Output ..........................................................................................................................34
VAV Heat Relay Output .........................................................................................................35
Supply Air Temperature Reset .............................................................................................35
COMMUNICATION ......................................................................................................................................35
DIRTY FILTER SWITCH ..............................................................................................................................35
FIELD CONTROL WIRING CONNECTIONS ..............................................................................................36
POWER WIRING .........................................................................................................................................37
ELECTRICAL SERVICE SIZING .................................................................................................................37
SINGLE-POINT POWER SUPPLY WIRING ...............................................................................................38
SINGLE-POINT POWER SUPPLY WIRING WITH NON-FUSED DISCONNECT SWITCH .......................39
DUAL-POINT POWER SUPPLY WIRING ...................................................................................................40
CONTROLS .................................................................................................................................................41
TRANSDUCER PNEUMATIC TUBING .......................................................................................................42
Static Pressure Control Plastic Tubing .............................................................................42
Duct Static Transducer .........................................................................................................42
Building Pressure Transducer .............................................................................................42
Static Pressure Probe Installation ......................................................................................42
DUCT SYSTEM ...........................................................................................................................................44
Duct Connection Guidelines ................................................................................................44
SOUND AND VIBRATION TRANSMISSION ..............................................................................................44
GAS HEATING ............................................................................................................................................45
GAS PIPING ................................................................................................................................................45
GAS CONNECTION ....................................................................................................................................45
Gas Piping Recommendations ............................................................................................45
COMBUSTION VENT ..................................................................................................................................46
SECTION 3 – START-UP ...................................................................................................................47
CRANKCASE HEATERS ............................................................................................................................47
CHECKING THE SYSTEM PRIOR TO INITIAL START (NO POWER) ......................................................47
Unit Checks ...........................................................................................................................47
UNIT CHECKS – POWER APPLIED ..........................................................................................................49
Verifying Compressor Rotation ...........................................................................................49
Compressor Oil Level Check ...............................................................................................49
JOHNSON CONTROLS
5
FORM 100.50-NOM6 (1207)
TABLE OF CONTENTS
INITIAL START-UP ......................................................................................................................................50
Refrigerant Charge ..............................................................................................................50
Checking Superheat and Subcooling .................................................................................50
Subcooling (R-410A) ............................................................................................................50
Superheat (R-410A) ..............................................................................................................50
Leak Checking ......................................................................................................................51
GAS HEAT MODELS ..................................................................................................................................53
Pre-Start Checks: ..................................................................................................................53
Post Start Checks: ................................................................................................................53
SECTION 4 – MAINTENANCE ..........................................................................................................55
GENERAL ...................................................................................................................................................55
PERIODIC MAINTENANCE – MONTHLY ...................................................................................................55
Filters .....................................................................................................................................55
Linkages ................................................................................................................................55
Compressors .........................................................................................................................55
Fan Bearing Lubrication .....................................................................................................55
Recommended Lubricant for Fan Bearings .......................................................................55
Condenser Coils ...................................................................................................................56
PERIODIC MAINTENANCE – THREE TO SIX MONTHS ..........................................................................56
Motor Bearing Lubrication ...................................................................................................56
Belt Tension ..........................................................................................................................56
PERIODIC MAINTENANCE – YEARLY ......................................................................................................56
Entire Unit Inspection ...........................................................................................................56
Sheave Alignment: ...............................................................................................................56
Belts .......................................................................................................................................56
Belt Replacement ..................................................................................................................57
Belt Tensioning: ....................................................................................................................57
Filter Drier Replacement ......................................................................................................58
Forward Curved Fans ...........................................................................................................58
Fan Motor ..............................................................................................................................59
Fan Shaft Bearings ...............................................................................................................59
Bearing Lock Devices ..........................................................................................................60
Eccentric Type ......................................................................................................................60
Torquing of Set-screws .......................................................................................................61
SECTION 5 – SEQUENCE OF OPERATION ....................................................................................63
UNIT TYPE ..................................................................................................................................................63
OCCUPIED / UNOCCUPIED MODE ...........................................................................................................63
CONSTANT VOLUME MODE (CV) .............................................................................................................63
Thermostat Input ..................................................................................................................64
Occupied Cooling ............................................................................................................64
Unoccupied Cooling ........................................................................................................64
Occupied Heating ............................................................................................................65
Unoccupied Heating ........................................................................................................65
6
JOHNSON CONTROLS
FORM 100.50-NOM6 (1207)
TABLE OF CONTENTS
Space Sensor – Hard Wired or Communicated .................................................................65
Cooling Operation – Occupied or Unoccupied .............................................................65
Heating Operation – Occupied or Unoccupied .............................................................66
Stand Alone ...........................................................................................................................66
Cooling Operation – Occupied or Unoccupied .............................................................67
Heating Operation – Occupied or Unoccupied .............................................................67
VARIABLE AIR VOLUME (VAV) .................................................................................................................68
Cooling - Occupied with Thermostat ..................................................................................68
Cooling – Unoccupied with Thermostat .............................................................................69
Occupied or Unoccupied Heating with a Thermostat .......................................................69
Occupied Cooling with Hard Wired or Communicated Space Sensor ............................69
Cooling – Unoccupied with a Hard Wired or Communicated Space Sensor .................70
Heating – Occupied with a Hard Wired or Communicated Space Sensor ......................70
Heating – Unoccupied with a Hard Wired or Communicated Space Sensor ..................70
Occupied Cooling – Stand Alone ........................................................................................71
Cooling – Unoccupied Stand Alone ...................................................................................72
Heating – Occupied Stand Alone ........................................................................................72
Heating – Unoccupied Stand Alone ....................................................................................72
CONDENSER FAN OPERATION ...............................................................................................................72
COOLING COMPRESSOR LOCKOUT .....................................................................................................72
Sequence of Operation .......................................................................................................72
LOW AMBIENT OPERATION ....................................................................................................................73
Operation and Pressure Control Range .............................................................................73
Confi guration (Jumpers and Potentiometers) ...................................................................73
SUPPLY FAN OPERATION .........................................................................................................................74
Constant Volume (CV) ..........................................................................................................74
Variable Air Volume (VAV) ....................................................................................................75
VAV Supply Fan Speed Control ...........................................................................................76
ECONOMIZER .............................................................................................................................................76
Dry Bulb .................................................................................................................................76
Single Enthalpy .....................................................................................................................77
Dual Enthalpy ........................................................................................................................77
BAS ECONOMIZER OPERATION .............................................................................................................77
Sequence of Operation .......................................................................................................78
Constant Volume Economizer Set Point ............................................................................78
Variable Air Volume Economizer Set Point ........................................................................78
Economizer / Compressor Operation .................................................................................79
Economizer PI Loop (Proportional and Integral) ...............................................................79
ECONOMIZER LOADING ...........................................................................................................................79
Constant Volume ..................................................................................................................80
Variable Air Volume ..............................................................................................................80
JOHNSON CONTROLS
7
FORM 100.50-NOM6 (1207)
TABLE OF CONTENTS
COMFORT VENTILATION ..........................................................................................................................81
Sequence of Operation ........................................................................................................82
Conditions of Operation .......................................................................................................82
EXCESSIVE SAT (SUPPLY AIR TEMPERATURE) CONTROL .................................................................82
Cooling ..................................................................................................................................82
Heating ...................................................................................................................................83
SPACE SENSOR WITH SET POINT ADJUSTMENT .................................................................................84
Sequence of Operation ........................................................................................................84
SPACE SENSOR FAULT OVERRIDE ENABLE ........................................................................................85
Sequence of Operation ........................................................................................................85
REMOTE CONTROL ...................................................................................................................................85
Sequence of Operation ........................................................................................................85
REDLINE .....................................................................................................................................................85
Sequence of Operation ........................................................................................................85
LOADSHED .................................................................................................................................................86
Sequence of Operation ........................................................................................................86
DIRTY FILTER .............................................................................................................................................86
Sequence of Operation ........................................................................................................86
METRIC OPERATION .................................................................................................................................86
INTELLI-START ..........................................................................................................................................86
Sequence of Operation ........................................................................................................87
Subsequent Operation .........................................................................................................87
MORNING WARM-UP .................................................................................................................................88
Sequence of Operation ........................................................................................................88
HYDRONIC HEAT .......................................................................................................................................89
Sequence of Operation ........................................................................................................89
HYDRONIC HEAT FREEZE STAT ..............................................................................................................89
VENTILATION .............................................................................................................................................89
Manual ...................................................................................................................................90
Fixed Minimum ......................................................................................................................90
Sequence of Operation ........................................................................................................90
Demand Ventilation ..............................................................................................................90
Defi nitions ........................................................................................................................91
Sequence of Operation ....................................................................................................91
VENTILATION LOW AMBIENT MINIMUM POSITION RESET ..................................................................91
Sequence of Operation ........................................................................................................91
EXHAUST FAN OPERATION .....................................................................................................................92
On/Off Control Based on Outdoor Damper Position .........................................................92
Sequence of Operation ....................................................................................................92
On/Off Control Based on Building Pressure ......................................................................92
Sequence of Operation ....................................................................................................93
8
JOHNSON CONTROLS
FORM 100.50-NOM6 (1207)
TABLE OF CONTENTS
Modulating Damper with Fixed Speed Exhaust .................................................................93
Sequence of Operation ....................................................................................................93
Modulating Exhaust with a VFD ..........................................................................................93
Sequence of Operation ....................................................................................................94
PRE-OCCUPANCY PURGE ........................................................................................................................94
Criteria for Operation ...........................................................................................................94
Sequence of Operation ........................................................................................................94
ENERGY RECOVERY VENTILATOR .........................................................................................................95
Sequence of Operation ........................................................................................................95
LOW VOLTAGE PROTECTION ..................................................................................................................95
OUTDOOR AIR HEATING LOCKOUT ........................................................................................................95
HOT GAS BYPASS .....................................................................................................................................95
SPACE TEMPERATURE ALARM ...............................................................................................................95
Sequence of Operation ........................................................................................................96
SAT ALARM FOR HEATING .......................................................................................................................96
Sequence of Operation ........................................................................................................96
“Supply Air Temp Alarm Setpoint for Heating” Alarm .................................................96
“Economizer Minimum Position” Alarm ........................................................................97
SAT ALARM FOR COOLING ......................................................................................................................97
Sequence of Operation ........................................................................................................97
“Supply Air Temp Alarm Setpoint for Cooling” Alarm .................................................97
“Economizer Minimum Position” Alarm ........................................................................98
ALARM HISTORY .......................................................................................................................................98
SECTION 6 – USER INTERFACE .....................................................................................................99
UNIT CONTROLLER INTERFACE .............................................................................................................99
PROGRAM BUTTON ..................................................................................................................................99
TEST/UP BUTTON ....................................................................................................................................100
ADDRESS/DOWN BUTTON .....................................................................................................................100
ALARM/CHANGE .....................................................................................................................................100
CHARACTER DISPLAY ADDRESSES & CODES ...................................................................................100
COMMUNICATION USING SIMPLICITY PC ............................................................................................104
Simplicity PC Download .....................................................................................................104
USB Adapter Drive - Simplicity Pocket PC .......................................................................106
Establishing Communication ............................................................................................107
Simplicity PC Data Screens ............................................................................................... 111
Revising Settings ................................................................................................................126
SECTION 7 – PARAMETER DESCRIPTIONS AND OPTIONS ......................................................141
SECTION 8 – SERVICE ...................................................................................................................153
ANALOG INPUT OPERATION .................................................................................................................153
Temperature Sensors .........................................................................................................153
Duct Pressure Transducer .................................................................................................153
JOHNSON CONTROLS
9
FORM 100.50-NOM6 (1207)
TABLE OF CONTENTS
Return Fan Pressure Transducer ......................................................................................154
Discharge Pressure Transducer ........................................................................................154
Building Pressure Transducer ...........................................................................................154
Suction Pressure Transducer ............................................................................................155
Humidity Sensors ...............................................................................................................155
Sensor ..........................................................................................................................156
CO
2
Furnace Status Input ..........................................................................................................156
FAULTS AND LOCKOUTS .......................................................................................................................160
Light Emitting Diode ...........................................................................................................160
Alarm Codes ........................................................................................................................160
Alarm Trouble Shooting .....................................................................................................163
Refrigerant System Alarm Codes (01, 02, 03, 04, 09, 10, 11, 12) ................................163
Low Pressure Cutout Alarm (09, 10, 11, 12) .................................................................164
Limit Switch Alarms (13, 14, 15) ...................................................................................164
Gas Heating Alarms (16, 17, 18) ....................................................................................164
Space Temperature Sensor Alarm (19) ........................................................................164
Supply Air Temperature Sensor Alarm (20) .................................................................165
Return Air Temperature Sensor Alarm (21) .................................................................165
Outdoor Air Temperature Sensor Alarm (22) ...............................................................165
Dirty Filter Switch Alarm (23) ........................................................................................165
Supply Fan Air Proving Switch (24) .............................................................................165
Supply Fan Air Proving Switch Closed Alarm (25) .....................................................165
Microelectronics Failure Alarm (26) .............................................................................165
Microelectronics Failure Alarm (27) .............................................................................165
Supply Fan Overload Alarm (28) ...................................................................................165
Outdoor Humidity Sensor Alarm (29) ...........................................................................166
Return Humidity Sensor Alarm (30) .............................................................................166
IAQ (CO2) Sensor Alarm (31) ........................................................................................166
Time Clock Error Alarm (32) ..........................................................................................166
Space Temperature Offset Alarm (33) ..........................................................................166
CV/VAV Input Alarm (34) ................................................................................................166
Low Voltage Alarm (35) ..................................................................................................166
Smoke Purge Mode Alarm (36) .....................................................................................166
High Duct Static Pressure Alarm (37) ..........................................................................166
Supply Air Temperature Cooling Alarm (38) ................................................................167
Supply Air Temperature Heating Alarm (39) ................................................................167
Economizer Minimum Position Alarm (40) ..................................................................167
Space Temperature Trending Alarm (41) .....................................................................167
Duct Static Low Pressure Alarm (42) ...........................................................................167
Hot Water Coil Freeze Alarm (43) .................................................................................167
10
JOHNSON CONTROLS
FORM 100.50-NOM6 (1207)
LIST OF TABLES
TABLE 2-1 – VOLTAGE LIMITATIONS .............................................................................................17
TABLE 2-2 – UNIT WEIGHTS - 050-061 MODELS ...........................................................................20
TABLE 2-3 – UNIT CENTER OF GRAVITY .......................................................................................20
TABLE 2-4 – UNIT CORNER WEIGHTS - 050-061 MODELS ..........................................................21
TABLE 2-5 – PHYSICAL DATA – 050-061 MODELS .......................................................................23
TABLE 2-6 – PHYSICAL DATA - COMPRESSORS ..........................................................................24
TABLE 2-7 – COMPRESSOR DATA - R410A ...................................................................................29
TABLE 2-8 – POWER SUPPLY VOLTAGE LIMITS ..........................................................................29
TABLE 2-9 – SUPPLY AND EXHAUST FAN MOTOR DATA - ODP .................................................30
TABLE 2-10 – SUPPLY AND EXHAUST FAN MOTOR DATA - TEFC .............................................30
TABLE 2-11 – CONDENSER FAN MOTOR RLA - STANDARD FAN ...............................................30
TABLE 2-12 – CONDENSER FAN MOTOR RLA - LOW SOUND FAN (FUTURE OPTION) ...........30
TABLE 2-13 – MISCELLANEOUS ELECTRICAL DATA ..................................................................30
TABLE 2-14 – ELECTRIC HEAT .......................................................................................................31
TABLE 2-15 – AIRFLOW AND ENTERING AIR/AMBIENT LIMITATIONS .......................................31
TABLE 2-16 – THREE PHASE POWER SUPPLY CONDUCTOR SIZE RANGE .............................41
TABLE 2-17 – SUPPLY AIR DUCT CONNECTION CONFIGURATIONS .........................................44
TABLE 2-18 – RETURN AIR DUCT CONNECTION CONFIGURATIONS ........................................44
TABLE 2-19 – PIPE SIZES ................................................................................................................45
TABLE 3-1 –R410-A PRESSURE / TEMPERATURE CHART .........................................................52
TABLE 3-2 – LOW FIRE / HIGH FIRE PRESSURES ............................................................................54
TABLE 3-3 – GAS HEAT PERFORMANCE DATA ............................................................................54
TABLE 4-1 – FAN BEARING – LUBRICATION INTERVALS ...........................................................55
TABLE 4-2 – SET SCREW TORQUE ................................................................................................61
TABLE 5-1 – BINARY OUTPUTS ......................................................................................................73
TABLE 5-2 – VFD JUMPERS ............................................................................................................73
TABLE 5-3 – POTENTIOMETER SETTINGS ....................................................................................73
TABLE 5-4 OPERATION DURING OFF CYCLE ..............................................................................81
TABLE 5-5 COMPRESSOR ON WHEN SPACE INPUT SATISFIED ................................................81
TABLE 5-6 HEAT STAGE ON WHEN SPACE INPUT SATISFIED ..................................................82
TABLE 6-1 - PARAMETER POINTS LIST .......................................................................................101
TABLE 6-2 - SIMPLICITY ELITE DATA MAP .................................................................................130
TABLE 7-1 – DEFINITIONS .............................................................................................................141
TABLE 8-1 – TEMPERATURE SENSOR RESISTANCE ................................................................153
TABLE 8-2 – DUCT PRESSURE TRANSDUCER ...........................................................................154
TABLE 8-3 – BUILDING PRESSURE TRANSDUCER OUTPUT ...................................................154
TABLE 8-4 – RETURN FAN PRESSURE TRANSDUCER OUTPUT ..............................................154
TABLE 8-5 – PRESSURE TRANSDUCERS ...................................................................................155
TABLE 8-6 – HUMIDITY SENSOR OUTPUTS ................................................................................155
TABLE 8-7 – CO2 SENSOR OUTPUT ............................................................................................156
TABLE 8-8 – WIRING DATA ............................................................................................................157
TABLE 8-9 – ALARM CODE DESCRIPTIONS ...............................................................................161
JOHNSON CONTROLS
11
FORM 100.50-NOM6 (1207)
LIST OF FIGURES
FIG. 1-1 – PACKAGED ROOFTOP AIR CONDITIONING UNIT ......................................................13
FIG. 2-1 – UNIT CLEARANCES ........................................................................................................18
FIG. 2-2 – LIFTING LUG LOCATIONS ..............................................................................................19
FIG. 2-3 – UNIT RIGGING .................................................................................................................19
FIG. 2-4 – GENERAL ARRANGEMENT DRAWING .........................................................................25
FIG. 2-5 – GENERAL ARRANGEMENT DRAWING ........................................................................28
FIG. 2-6 – DRAIN TRAP SHOWING WATER LOCATION DURING DRAW THROUGH
OPERATION STAGES ......................................................................................................32
FIG. 2-7 – TRAP DETAIL FOR DRAW THROUGH APPLICATION ..................................................32
FIG. 2-8 – FIELD CONTROL WIRING CONNECTIONS ...................................................................36
FIG. 2-9 – SINGLE-POINT POWER SUPPLY WIRING .....................................................................38
FIG. 2-10 – SINGLE-POINT POWER SUPPLY WIRING WITH NON-FUSED DISCONNECT .........39
FIG. 2-11 – DUAL-POINT POWER SUPPLY WIRING ......................................................................40
FIG. 2-12 – ATMOSPHERIC SENSOR PROBE ................................................................................43
FIG. 2-13 – TYPICAL GAS PIPING CONNECTION ..........................................................................45
FIG. 2-14 – COMBUSTION VENT .....................................................................................................46
FIG. 3-1 – FAN HOLD DOWN BRACKETS .......................................................................................48
FIG. 3-2 – MANIFOLD GAS PRESSURE ADJUSTMENT ................................................................54
FIG. 4-1 – SHEAVE ALIGNMENT ......................................................................................................56
FIG. 4-2 – FAN DATA PLATE - BELT TENSION ...............................................................................57
FIG. 4-3 – BELT TENSIONING GAUGE ............................................................................................57
FIG. 4-4 – EXAMPLE OF FC FAN SHAFT/WHEEL MARKING ........................................................58
FIG. 4-5 – BEARING WITH SETSCREW TYPE LOCKING DEVICE ................................................60
FIG. 4-6 – BEARING WITH ECCENTRIC CAM ................................................................................60
FIG. 4-7 – ECCENTRIC CAM LOCKING COLLAR BEARING INSTALLATION ..............................61
FIG. 4-8 – SPLIT BEARING ...............................................................................................................61
FIG. 5-1 – CONDENSER FAN VFD POTENTIOMETER SETTINGS ................................................73
FIG. 6-1 – UNIT CONTROLLER INTERFACE ...................................................................................99
FIG. 8-1 – CONNECTOR LOCATIONS ...........................................................................................157
12
JOHNSON CONTROLS
SECTION 1 – INTRODUCTION
FORM 100.50-NOM6 (1207)
1
FIG. 1-1 – PACKAGED ROOFTOP AIR CON DI TION ING UNIT
ECOLOGICAL AND ECONOMICAL DESIGN
• High Effi ciency eco
2
rooftop units are optimized
Condensing Section
for HFC-410A refrigerant. YORK provides the
FIRST standard product offering that meets the
latest ASHRAE 90.1 energy effi ciency requirements.
• Cooling and Heating – Superior op er at ing per-
for mance provides lower operating costs. Smaller
steps of cool ing capacity pro vide tighter con trol
of build ing environment and oc cu pant comfort
while optimizing energy effi ciency.
• Indoor Air Quality (IAQ) – Outside air econ-
o miz ers pro vide en er gy sav ings in free cooling
mode, and can pro vide a health i er and more
comfortable build ing en vi ron ment by in tro duc ing
fresh outside air into the build ing as needed. Indoor Air Quality (IAQ) re quire ments for building
ventilation and com fort are con trolled through
the microprocessor con trol pan el.
• Premium-Effi ciency Motors – Premium-effi -
ciency motors are available for optimum energy
effi ciency. All mo tors used on the eco2 pack aged
roof top air con di tion er meet U.S. EPACT 1992
min i mum re quire ments.
High-effi ciency motors are standard. Motors are
available in ODP or TEFC construction.
LD13271
• Scroll Compressors – Reliable, efficient,
trouble-free operation is the true measure of a
packaged rooftop’s value. That’s why YORK
2
eco
Packaged Rooftop Air Conditioners use
established scroll-compressor technology to
deliver dependable, eco nom i cal performance
in a wide range of ap pli ca tions. With the eco
Packaged Rooftop, you get the latest generation
of compressor en hance ments added to the scroll’s
inherent strengths. The sim plic i ty of a hermetic
scroll compressor allows the use of fewer moving
parts to minimize breakdown.
• Multiple Compressor Staging – Through the
2
use of the scroll compressor, the eco
ity to stage it’s cooling by enabling and disabling
mul ti ple single stage compressors on multiple
circuits. These compressors are manifolded together in two independent circuits.
• Compressor Circuiting – The eco
so that only 2 scroll compressors are in tandem
within one refrigeration circuit. This means more
reliable com pres sors, and less equipment down
time. With multiple circuits, if a compressor
should ever fail on one circuit, the other circuit/s
will re main op er a tion al to work to maintain occupied loads. The eco2 sys tem has 2 circuits in
the unit.
has the abil-
2
is designed
2
JOHNSON CONTROLS
13
Introduction
FORM 100.50-NOM6 (1207)
Compressor Sound Blankets – Optional factory
•
in stalled sound blankets can be installed to further
reduce com pres sor sound attenuation.
• Replaceable core fi lter driers – The optional
2
re place able core fi lter driers on the eco
provides
a con ve nient means for maintaining and optimizing the units refrigeration system. Eliminating
ad di tion al fi eld pen e tra tions into the refrigerant
circuit, which could lead to potential problems,
reduce the worry of re frig er ant circuit contamination.
• Low Ambient Operation – Head-pressure con-
trol is accomplished via a VFD motor controller
rather than an ineffi cient and noisy condenser fan
damper. By varying the speed of the condenser
fan, better control and quieter operation is obtained during the colder months. Low ambient
controls are available on all systems offering
higher rooftop cooling capacity than competitive
units.
• Condenser Fan Motors – The condenser fan
2
mo tors used on the eco
unit are Totally Enclosed
Air Over (TEAO) to provide maximum durability
through any season.
• Condenser Coils – Are available in various
ma te ri als and coatings to suit almost any type of
ap pli ca tion. Alu mi num or copper fi ns, pre-coat ed
or post-coated fi ns are available. The coating is
applied us ing an epoxy coating on the aluminum
coil. Each coil option is benefi cial when the unit
must operate under ex treme con di tions. The use
of an epoxy coated coil is recommended for units
installed in a corrosive environment.
Heating Section
• Staged gas heat – The eco
2
rooftop gas furnace
is an induced-draft gas furnace designed for
high ef fi cien cy and reliability. The furnace uses
an alu mi nized steel tubular heat exchanger and
op er ates at tem per a tures suffi cient to prevent
acidic ex haust gases from con dens ing in the
heat ex chang er at low fi re rates, unlike drum and
tube style fur nac es that generate condensation
for ma tion. Up to three stages of heat are available.
An optional stainless steel heat exchanger is also
available.
• Electric – The eco
2
is also available with an
elec tri cal heater that can range from 40kW up to
50kW. De pend ing on the size of the heat re quired,
2
the eco
can have 3 steps of control helping to
provide tighter control of the supply and zone
con di tioned air. With the uti li za tion of this multi
step func tion, the eco2 can ef fec tive ly reduce en er gy con sump tion by bring ing on smaller stages
of heat while main tain ing the max i mum level of
com fort.
• Steam and Hot water – This option will be
available in the future.
• Hot Gas By-pass – Is standard on VAV units.
• Condenser Coil Protection – The eco
able with a wire mesh guard for optimum coil
protection.
14
2
is avail-
JOHNSON CONTROLS
AIR MANAGEMENT
FORM 100.50-NOM6 (1207)
1
• DWDI Airfoil fans – High effi ciency fans are
used to im prove ap pli ca tion fl exibility, and address sound and ap pli ca tion con cerns.
• Building pressure control – Ex haust fans and
barometric relief dampers are available to meet
building pressure control requirements. Select
the most appropriate option for a given ap pli ca tion.
• Low sound options – Allow for application of
the eco2 unit in sound-sensitive applications
such as the aters and downtown areas. Contact
JOHNSON CONTROLS for more details on
site-specifi c requirements.
• Variable Frequency Drives – When a VAV unit
is or dered, the eco2 comes standard with vari able
fre quen cy drives (VFD’s). The VFD can optimize
a sys tems performance by modulating the sup ply
fan motor speed to reduce energy con sump tion
by as much as 40% while maximizing oc cu pant
comfort.
• Fan Spring Isolation – Two-inch spring iso la tion
is used to prevent vibration transmission from the
roof top unit’s supply fan to the building.
The control can also be connected to a computer
for greater access to programming and operating
information.
• Communication -The controller is designed
to communicate using Modbus RTU protocol.
Through the addition of a ModLINC translator,
the unit can also communicate using BACnet
MS/TP protocol.
INDOOR AIR QUALITY
• Double Sloped Stainless Steel Drain Pan – The
eco2’s standard Stainless Steel drain pan meets
ASHRAE 62 requirements for condensate drain-
age to improve indoor air quality. Solid wall liners
encase insulation and prevent moisture dam age.
Additional benefi ts include easy cleanability and
isolates insulation from conditioned airstream.
• Double Wall Construction – Is the standard
con struc tion of the eco2 and incorporates powder
coat ed pre-fabricated outer panels and corner post
for max i mum exterior surface protection.
CONTROLS
• Rooftop Controller - The unit is designed to
use the Simplicity Elite control. This control
has been used with the 25 to 40 ton Millennium
product for many years. The control is designed
to operate with conventional room control input.
This allows the same control to be used on installations requiring 25 to 60 tons of cooling.
The board is equipped with four program but-
tons and two character displays for use by the
technician. They allow for access to the most
important board functions, current operating
data, and current alarms as well as the last fi ve
alarms in the history memory buffer. The buttons
and displays are also used to program the control
with the correct confi guration and set points.
JOHNSON CONTROLS
15
Introduction
FORM 100.50-NOM6 (1207)
Factory Shrinkwrap – All eco2 rooftop units
•
can be ordered from the factory with an optional
factory-fresh shrinkwrap pack ag ing. This eliminates the contractors worries about dirt and debris
clogging up condenser coils or moisture leaking
into the air han dler on the units way to the job
site or rigging yard.
• Demand Ventilation Option – Can be incorpo-
rated into the unit to improve indoor air quality
and help manage indoor pollutants such as CO
or other harmful air borne con tam i nates out of
the occupied spaces for maximum comfort and
safety. Activation of this se quence can easily be
ac com plished using a CO2 sensor installed in the
conditioned space. CO2 sensors are typically
used with de mand ventilation; however other
sensors may be applied to control indoor con tam i nants such as volatile or gan ic com pounds
(VOCs).
• Smoke Purge – Is also available to evacuate
smoke due to fi re from a room or zone.
• Filtration – The eco
types of fi ltration to meet the different needs and
re quire ments of today's rooftop applications,
including 2-inch throwaway, pleated, carbon,
and cleanable fi l ters and 12-inch high effi ciency
rigid fi lters.
ELECTRICAL
• Single Point Power – The eco
dard with single point power connections to make
in stal la tion quick and easy.
2
is confi gured for various
2
unit comes stan-
SERVICE AND INSTALLATION
• Access Doors – Full-sized access doors provide
easy access into the unit for routine maintenance
and inspection.
The unit can be purchased with a “Both Side
Access” option for additional accessibility.
• Service Valves – Oversized ser vice valves to
pro vide iso la tion and quick rec la ma tion and
2
charg ing of sys tem re frig er ant are avail able as
an option to min i mize down time and sim pli fy
the service and repair task.
• Convenience Outlet – For maintenance tasks
re quir ing power tools, an optional 110V GFCI
pow er supply can power lights, drills or any other
power hand tool needed.
• Factory Run-Tested – Each unit is subjected
to a series of quality assurance checks as well
as an au to mat ed quality control process before
being run-tested. Fans and drives are balanced
at the fac to ry during testing. The factory run-test
ensures safe proper operation when the unit is
installed, and reduces installation and commissioning time.
• Gas Heat Sections – Are factory and leaked
checked.
• Replaceable Core Filter Drier Option – Pro-
vides a means to remove moisture, dirt and debris
from the re frig er a tion circuit in the event it is
opened.
• Dual Point Power – Can be factory installed for
ap pli ca tions that require the mechanical heating
and cooling functions to be separated from the
air han dling functions. This enables the unit to
be op er at ed in an emergency condition while
minimizing power consumption.
• Unit-Mounted Disconnect – Is available as an
op tion to minimize time at installation of equipment and to reduce necessary field installed
items.
16
JOHNSON CONTROLS
SECTION 2 – INSTALLATION
FORM 100.50-NOM6 (1207)
APPROVALS
Designed certifi ed by CSA, ETL, CETL as follows:
1. For use as a forced air furnace with cooling unit
(gas heat models).
2. For outdoor installation only.
3. For installation on combustible ma te ri al and may
be installed directly on combustible fl oor ing or
Class A, Class B or Class C roof covering ma te ri als.
4. For use with natural gas or LP.
5. When used with LP propane gas one of the following conversion kits must be installed before the gas
heat section is fi red:
375,000 BTU Input - 385-01866-001
750,000 BTU Input - 385-01866-002
1,125,000 BTU Input - 385-01866-003
Not suitable for use with conventional venting
systems.
LIMITATIONS
The installation of this unit must conform to local
build ing codes, or in the absence of local codes, with
ANSI 223.1 Natural Fuel Gas Code and /or CAN/CGA
B149 in stal la tion codes.
In U.S.A.:
1. National Electrical Code ANSI/NFPA No. 70 - Latest Edition.
2. National Fuel Gas Code Z223.1 - Latest Edition.
3. Gas-Fired Central Furnace Standard ANSI Z21.47
- Latest Edition.
4. Local gas utility requirements.
TABLE 2-1 – VOLTAGE LIMITATIONS
UNIT POWER
SUPPLY
575-3-60 518 632
480-3-60 415 506
230-3-60 207 253
200-3-60 187 228
VOLTAGE VARIATIONS
MIN. VOLTS MAX. VOLTS
Refer to Table 2-15 for airfl ow and entering air/ambient
conditions limitations, and Table 2-1 for voltage
limitations.
If the VAV boxes in the conditioned
space have hydronic heating coils
installed, it is the responsibility of the
installing contractor to take appropriate measures to protect the hydronic
coils against low unit supply air temperatures that could result in the freeze
up and rupture of the coils.
UNIT INSPECTION
Immediately upon receiving the unit, it should be
in spect ed for possible damage, which may have
oc curred during transit. If damage is evident, it should
be noted in the car ri er’s freight bill. A writ ten re quest
for in spec tion by the carrier’s agent should be made at
once. See “In struc tion” man u al, Form 50.15-NM for
more in for ma tion and de tails.
To ensure warranty cov er age, this
equip ment must be commissioned and
serviced by an authorized JOHNSON
CONTROLS ser vice mechanic or a
qual i fi ed service person ex pe ri enced
in pack aged roof top in stal la tion.
In stal la tion must comply with all ap pli ca ble codes, par tic u lar ly in regard
to elec tri cal wir ing and other safety
el e ments such as relief valves, HP
cut-out settings, de sign work ing pres sures, and ven ti la tion re quire ments
con sis tent with the amount and type
of re frig er ant charge.
Lethal voltages exist within the con trol
panels. Before servicing, open and tag
all dis con nect switches.
LOCATIONS AND CLEARANCES
GENERAL
The eco2 air conditioning units are designed for outdoor
installation. When selecting a site for installation, be
guided by the following conditions:
• Unit must be installed on a level surface.
• For the outdoor location of the unit, select a place
having a minimum sun exposure and an adequate
supply of fresh air for the condenser.
2
JOHNSON CONTROLS
17
Installation
FORM 100.50-NOM6 (1207)
• Also avoid locations beneath windows or between structures.
• Optional condenser coil protection should be used
for seashore locations or other harsh environments.
• The unit should be installed on a roof that is structurally strong enough to support the weight of the unit
with a minimum of defl ection. It is recommended
that the unit(s) be installed not more than 15 feet
from a main support beam to provide proper
structural support and to minimize the transmission of sound and vibration. Ideally, the center of
gravity should be located over a structural support
or building column.
• Location of unit(s) should also be away from
building fl ue stacks or exhaust ventilators to
prevent possible reintroduction of contaminated
air through the outside air intakes.
• Be sure the supporting structures will not obstruct
the duct, gas or wiring connections.
away from sound sensitive areas such as conference
rooms, auditoriums and executive offi ces and any other
room that may have potential for tenant occupancy.
Possible locations could be above hallways, mechanical
or utility rooms.
Finally, service clearances should be maintained in
rooftop design to insure safe access to the unit. Unit
clearances are designed so that technicians have enough
space between units, building walls, and edges of
building to gain access safely. In cases where space is
limited, please call your local York representative for
additional information.
The clearances shown are to provide
adequate condenser airfl ow and service access to inside the unit. Additional clearance should be considered
for component replacement such as
compressors, evaporator coils, and
supply or exhaust fans.
LOCATION
Of the many factors that can effect the location of
equipment, some of the most important to consider are
Structural, Acoustical and Service clearances. Proper
attention should be made at the design stage to ensure
proper structural support. In cases where equipment is
being replaced, be aware of building design to insure
support is adequate for the application.
The next most important consideration in applying roof
top equipment is that of sound from the equipment.
Special care should be made to keep the roof top unit
While it is a common practice to operate the fan as soon as possible (air
movement during construction) on the
job site, the incomplete ductwork and
missing diffuser grilles will greatly
reduce air resistance and will allow
the fan to operate beyond design parameters. This practice may result in
water carry over and fl ooding of the
unit. Also, the supply fan motor may
overamp and become damaged.
96"
NOTES:
1. 10' clearance minimal over the top of the condensing unit.
2. Only one adjacent wall can exceed unit height.
3. 12' clearance required to adjacent units.
FIG. 2-1 – UNIT CLEARANCES
18
LD13267
4. 8' service access recommended on one side.
5. Economizer and exhaust hoods, where applicable, are folded
inside unit for shipment.
6. Dim. is to outside of lifting lugs.
JOHNSON CONTROLS
RIGGING AND HANDLING
Proper rig ging and handling of the equip ment is
man da to ry during un load ing and setting it into position
to re tain warranty status. All lifting lugs must be used
to pre vent twisting and damage to the unit.
Care must be taken to keep the unit in the upright
po si tion during rigging and to prevent damage to the
water-tight seams in the unit casing. Avoid unnecessary
jar ring or rough handling.
Typical rigging using proper spreader bars and cables
is shown in Figure 2-3. See Figure 2-2 for number
and location of the lifting lugs by unit size. It is also
mandatory that an ex pe ri enced and reliable rigger be
selected to han dle un load ing and fi nal place ment of
the equipment. The rig ger must be advised that the unit
contains internal com po nents and that it be han dled in
an upright po si tion. Care must be exercised to avoid
twisting the equip ment struc ture.
Unit weights are listed under Table 2-2 in this manual.
These weights must be re ferred to when selecting a crane
for rig ging and fi guring roof weight loads. Con tact your
FORM 100.50-NOM6 (1207)
2
00543vip
FIG. 2-3 – UNIT RIGGING
JOHNSON CONTROLS Sales Offi ce if you have any
ques tions re gard ing unit weights.
%
+
7
'
,
:
(
'
,
6
7
8
2
$
UNIT SIZE TONS
LENGTH
INCHES
UNIT
2876,'(/(1*7+
DIMENSION
1-2 3-4 5-6 7-8 9-10
50 - 61 STD CABINET 339 16.91 79.21 147.93 207.81 315.04
FIG. 2-2 – LIFTING LUG LOCATIONS
LD13272
&
&21'(16(5(1'
'
JOHNSON CONTROLS
19
Installation
FORM 100.50-NOM6 (1207)
UNIT WEIGHTS
TABLE 2-2 – UNIT WEIGHTS - 050-061 MODELS
MODEL SIZE 050 051 060 061
BASIC UNIT* 7433 7433 7800 7819
ECONOMIZERS
NO OUTSIDE AIR 240 240 240 240
25% OUTSIDE AIR FIXED POSITION MAUAL
DAMPER
25% OUTSIDE AIR 2 POSITION ACTUATED
DAMPER
FULL MODULATION WITH MINIMUM POSITION 476 476 476 476
POWER EXHAUSTS
FAN, MOTOR, MODULATING DAMPER AND HOOD 501 501 501 501
FAN, MOTOR, VFD, BAROMETRIC DAMPER AND
HOOD
GAS HEAT
375 MBH 162 162 162 162
750 MBH 324 324 324 324
1125 MBH 486 486 486 486
OPTIONS
OPEN PERIMETER CURB 544 544 544 544
CONDENSER COIL WIRE GUARD 64 64 64 64
COPPER CONDENSER COILS (ADDITIONAL) 516 516 773 773
12” RIGID FILTERS (ADDITIONAL) 319 319 319 319
*UNIT INCLUDES FC FAN W/ 20 HP MOTOR, VFD AND 2” THROWAWAY FILTERS
446 446 446 446
476 476 476 476
506 506 506 506
Center of Gravity
B C
Condenser
92
Y
A
D
Coil End
339
LD08298
TABLE 2-3 – UNIT CENTER OF GRAVITY
MODEL
BASIC UNIT 184.1 50.2 184.1 50.2
BASIC UNIT W/ ECON. 191.0 49.9 191.0 49.9
BASIC UNIT W/ ECON. & HEATING 187.4 50.0 187.4 50.0
BASIC UNIT W/ ECON. & HEATING & POWER
EXHAUST
MODEL
BASIC UNIT 179.8 49.9 179.6 50.0
BASIC UNIT W/ ECON. 186.7 49.7 186.5 49.7
BASIC UNIT W/ ECON. & HEATING 183.5 49.8 183.2 49.8
BASIC UNIT W/ ECON. & HEATING & POWER
EXHAUST
XYXY
194.9 49.5 194.9 49.5
XYXY
190.9 49.3 190.7 49.3
20
050 051
060 061
JOHNSON CONTROLS
FORM 100.50-NOM6 (1207)
UNIT WEIGHTS (CONTINUED)
TABLE 2-4 – UNIT CORNER WEIGHTS - 050-061 MODELS
MODEL
BASIC UNIT 1835 2201 1852 1545 1835 2201 1852 1545
BASIC UNIT W/ ECON. 2039 2417 1873 1580 2039 2417 1873 1580
BASIC UNIT W/ ECON. & HEATING 2118 2521 2041 1715 2118 2521 2041 1715
BASIC UNIT W/ ECON. & HEATING & POWER
EXHAUST
ABCDABCD
2366 2751 2034 1750 2366 2751 2034 1750
050 051
2
MODEL
BASIC UNIT 1894 2244 1986 1676 1893 2250 1997 1680
BASIC UNIT W/ ECON. 2097 2461 2008 1711 2096 2466 2018 1715
BASIC UNIT W/ ECON. & HEATING 2177 2565 2175 1846 2176 2570 2185 1850
BASIC UNIT W/ ECON. & HEATING & POWER
EXHAUST
ABCDABCD
2424 2795 2168 1881 2423 2801 2178 1885
060 061
Unit Placement
• Elevated – Elevated roof curbs or dunnage steel
can be used to support the unit in order to raise it
to specifi c heights. When this type of placement
is required, be sure to keep unit access in mind.
Cat walks or other forms of unit access may be
required to one or both sides of the unit, depending on your area of the country and the local codes
that are enforced. Please check with local offi cials
to ensure the application conforms to local codes
and regulations.
• Ground Level Locations – It is important that
the units be installed on a substantial base that
will not settle, causing strain on the refrigerant
lines and sheet metal and resulting in possible
leaks. A one piece concrete slab with footers
extended below the frost line is highly recommended. Additionally, the slab should be isolated
from the main building foundation to prevent
noise and vibration transmission to the building
structure.
For ground level installations, precautions should
be taken to protect the unit from tampering by, or
injury to, unauthorized persons. Erecting a fence
around the unit is common practice.
JOHNSON CONTROLS
21
Installation
ROOF CURB INSTALLATION
YORK offers an optional roof curb designed specifi cally
for the eco2 foot print. This curb comes as an open
condenser model and is shipped disassembled and
requires fi eld assembly during installation. Refer to
the Installation Manual that is shipped with the roof
curb for specifi c instructions. For bottom supply and
return openings, the curb has matching connections to
ease installation.
The curb should be located according to the location
recommendations above, and properly sealed to prevent
moisture and air leakage into and out of the duct system.
Flexible collars should be used when connecting the
duct work to prevent unit noise transmission and
vibration into the building. The roof curb drawings
contained in the Johnson Controls literature are not
intended as construction documents for fi eld fabrication
of a roof curb. Johnson Controls will not be responsible
for the unit fi t up, leak integrity, or sound level with
fi eld fabricated roof curbs.
FORM 100.50-NOM6 (1207)
Construction documents for fi eld fabricated roof curbs
are available upon request.
Wood or fiber cant strips, roofing
felts, roofi ng material, caulking and
curb-to-roof fasteners are to be fi eld
supplied.
22
JOHNSON CONTROLS
FORM 100.50-NOM6 (1207)
PHYSICAL DATA
TABLE 2-5 – PHYSICAL DATA – 050-061 MODELS
UNIT SIZE 050 051 060 061
GENERAL DATA
LENGTH WITHOUT HOOD (INCHES) 339 339 339 339
WIDTH (INCHES) 92 92 92 92
HEIGHT (INCHES) 82 82 82 82
UNIT EER/ IPLV 10.3 / 10.9 10.2 / 10.6 10.1 / 10.4 10.1 / 10.3
UNIT EER/ IPV GAS HEAT
COMPRESSOR DATA (SEE TABLE 2-6)
QUANTITY 4 4 4 4
TYPE SCROLL SCROLL SCROLL SCROLL
UNIT CAPACITY STEPS 4 4 4 4
REFRIGERANT (410A)
SYSTEM 1 50 lbs - 0 oz 50 lbs - 0 oz 58 lbs - 11 oz 58 lbs - 11 oz
SYSTEM 2 50 lbs - 0 oz 50 lbs - 0 oz 58 lbs - 11 oz 58 lbs - 11 ozs
SUPPLY FAN
QUANTITY 1 1 1 1
TYPE FC FC FC FC
SIZE 28 - 28 28 - 28 28 - 28 28 - 28
MOTOR SIZE RANGE (HP) 10 - 40 10 - 40 10 - 40 10 - 40
AIR FLOW RANGE (CFM) COOLING MIN. 10,000 - 22,500 10,000 - 22,500 12,500 - 24,000 10,000 - 24,000
STATIC PRESSURE RANGE (TOTAL) 1.0” - 6.0” 1.0” - 6.0” 1.0” - 6.0” 1.0” - 6.0”
OPTIONAL SUPPLY FAN
QUANTITY 1 1 1 1
TYPE AF AF AF AF
SIZE 28 28 28 28
MOTOR SIZE RANGE (HP) 10 - 40 10 - 40 10 - 40 10 - 40
AIR FLOW RANGE (CFM) COOLING MIN. 10,000 - 22,500 10,000 - 22,500 10,000 - 24,000 10,000 - 24,000
STATIC PRESSURE RANGE (TOTAL) 1.0” - 8.0” 1.0” - 8.0” 1.0” - 8.0” 1.0” - 8.0”
EXHAUST FAN
QUANTITY FANS/MOTORS 2 / 1 2 / 1 2 / 1 2 / 1
TYPE FC FC FC FC
SIZE 18 - 18 18 - 18 18 - 18 18 - 18
MOTOR SIZE RANGE (HP) 5 - 20 5 - 20 5 - 20 5 - 20
AIR FLOW RANGE (CFM) 4,000 - 22,500 4,000 - 22,500 4,000 - 24,000 4,000 - 24,000
STATIC PRESSURE RANGE (TOTAL) 0.1” - 1.5” 0.1” - 1.5” 0.1” - 1.5” 0.1” - 1.5”
EVAPORATOR COIL
SIZE (SQUARE FEET) 52 52 52 52
ROWS/FPI 3 / 17 3 / 17 4 / 17 4 / 17
CONDENSER COIL
SIZE (SQUARE FEET) 88 88 88 88
ROWS/FPI 2 / 17 2 / 17 3 / 17 3 / 17
CONDENSER FANS
QUANTITY 4 4 4 4
TYPE PROP. PROP. PROP. PROP.
DIAMETER (INCHES) 36 36 36 36
MOTOR HP 2 2 2 2
FILTERS - 2” THROWAWAY (PRE-FILTER POSITION)
QUANTITY 8 / 12 8 / 12 8 / 12 8 / 12
SIZE (LENGTH X WIDTH) (IN.) 25X16 / 25X20 25X16 / 25X20 25X16 / 25X20 25X16 / 25X20
TOTAL FILTER FACE AREA (SQUARE FEET) 61.6 61.6 61.6 61.6
FILTERS - 2” CLEANABLE (PRE-FILTER POSITION)
QUANTITY 8 / 12 8 / 12 8 / 12 8 / 12
SIZE (LENGTH X WIDTH) (IN.) 25X16 / 25X20 25X16 / 25X20 25X16 / 25X20 25X16 / 25X20
TOTAL FILTER FACE AREA (SQUARE FEET) 63.9 63.9 63.9 63.9
2
JOHNSON CONTROLS
23
Installation
FORM 100.50-NOM6 (1207)
PHYSICAL DATA (CONTINUED)
TABLE 2-5 – PHYSICAL DATA - 050-061 MODELS (CONTINUED)
UNIT SIZE 050 051 060 061
FILTERS - 2” PLEATED, 30% EFFICIENT (PRE-FILTER POSITION)
QUANTITY 8 / 12 8 / 12 8 / 12 8 / 12
SIZE (LENGTH X WIDTH) (IN.) 25X16 / 25X20 25X16 / 25X20 25X16 / 25X20 25X16 / 25X20
TOTAL FILTER FACE AREA (SQUARE FEET) 63.9 63.9 63.9 63.9
FILTERS -12” RIGID 65%, 2” 30% PREFILTER (PRE-FILTER POSITION)
QUANTITY 1 / 4 / 9 1 / 4 / 9 1 / 4 / 9 1 / 4 / 9
SIZE (LENGTH X WIDTH) (IN.)
TOTAL FILTER FACE AREA (SQUARE FEET) 43.0 43.0 43.0 43.0
FILTERS -12” RIGID 95%, 2” 30% PREFILTER (PRE-FILTER POSITION)
QUANTITY 1 / 4 / 9 1 / 4 / 9 1 / 4 / 9 1 / 4 / 9
SIZE (LENGTH X WIDTH) (IN.)
TOTAL FILTER FACE AREA (SQUARE FEET) 44.6 44.6 44.6 44.6
FILTERS - 2” CARBON (PRE-FILTER POSITION)
QUANTITY 8 / 12 8 / 12 8 / 12 8 / 12
SIZE (LENGTH X WIDTH) (IN.) 25X16 / 25X20 25X16 / 25X20 25X16 / 25X20 25X16 / 25X20
TOTAL FILTER FACE AREA (SQUARE FEET) 63.9 63.9 63.9 63.9
FILTERS - 12” RIGID 95% IN POST-FILTER POSITION
QUANTITY 1 / 3 / 9 1 / 3 / 9 1 / 3 / 9 1 / 3 / 9
SIZE (LENGTH X WIDTH) (IN.)
TOTAL FILTER FACE AREA (SQUARE FEET) 41.8 41.8 41.8 41.8
GAS FURNACES
STAGED FURNACE SIZES (INPUT/OUTPUT/STEPS)
GAS PRESSURE RANGE 4.5-13.5" WC 4.5-13.5" WC 4.5-13.5" WC 4.5-13.5" WC
AIRFLOW RANGE
(MIN HEATING)
MINIMUM OA TEMP FOR MECH. CIG. 40.0 °F 40.0 °F 40.0 °F 40.0 °F
LOW AMBIENT OPTION MIN. OA TEMP 0.0 °F 0.0 °F 0.0 °F 0.0 °F
375 MBH 7,500 7,500 11,500 11,500
750 MBH 14,000 14,000 14,000 14,000
1125 MBH 21,000 21,000 21,000 21,000
16X20/25X16/
25X20
16X20/25X16/
25X20
16X20/25X16/
25X20
16X20/25X16/
25X20
16X20/25X16/
25X20
16X20/25X16/
25X20
375 MBH / 300 MBH / 1 STEP
750 MBH / 600 MBH / 2 STEPS
1125 MBH / 900 MBH / 3 STEPS
16X20/25X16/
25X20
16X20/25X16/
25X20
16X20/25X16/
25X20
16X20/25X16/
25X20
16X20/25X16/
25X20
16X20/25X16/
25X20
TABLE 2-6 – PHYSICAL DATA - COMPRESSORS
COMPRESSORS UTILIZED COMPRESSOR NOMINAL TONS
SYSTEM 1 SYSTEM 2 SYSTEM 1 SYSTEM 2
MODEL
“COMPR
050 ZP137 ZP120 ZP137 ZP120 13.58 12.53 13.58 12.53 26.0 52.0 76.0 100.0
051 ZP137 ZP137 ZP137 ZP137 13.58 13.58 13.58 13.58 25.0 50.0 75.0 100.0
060 ZP182 ZP137 ZP182 ZP137 17.95 13.30 17.95 13.30 28.7 57.4 78.7 100.0
061 ZP182 ZP137 ZP182 ZP154 17.95 13.30 17.60 14.86 28.2 55.8 76.7 100.0
# 1”
“COMPR
# 2”
“COMPR
# 3”
“COMPR
# 4”
24
“COMPR
# 1”
“COMPR
# 2”
“COMPR
# 3”
“COMPR
# 4”
CAPACITY %
“STAGE1”“STAGE2”“STAGE3”“STAGE
4”
JOHNSON CONTROLS
GENERAL ARRANGEMENT DRAWING – 050-061 MODELS
BOTTOM SUPPLY / BOTTOM RETURN
SECTION DESCRIPTIONS:
EE = Economizer
FE = Fan Exhaust
_F = Filter Segments
CC = Cooling Coils
FS = Supply Fan
DP = Discharge Plenum
CO = Condenser Section
60.00
CLEAR
FOR AIR
FORM 100.50-NOM6 (1207)
BOTH
SIDES
INTAKE
136.82
FRONT VIEW
2
339.00
170.31
ELECTRICAL SERVICE
86.50
69.83
75.58
5.50
5.74
4.56
OA OA
67.25
191.19
230.62
84.00
CLEAR
EE
_F
FS CC
FE
1-1/4" FPT
DRAINS
BOTH SIDES
1.50
46.00
60.00
39.00
AIRFLOW
TOP VIEW
120.00 CLEAR
91.00
PULL
CLEAR
FOR COIL
DP
CO
SIDE VIEW
(LEFT SIDE)
FIG. 2-4 – GENERAL ARRANGEMENT DRAWING
JOHNSON CONTROLS
82.00
92.00
100.50
REAR VIEW
SWING
30.00 DOOR
BOTH SIDES
CLEARANCE
78.00 CLEAR
FOR COIL PULL
LD08295
25
Installation
GENERAL ARRANGEMENT DRAWINGS (CONTINUED)
BOTTOM SUPPLY / SIDE RETURN
SECTION DESCRIPTIONS:
EE = Economizer
FE = Fan Exhaust
_F = Filter Segments
CC = Cooling Coils
FS = Supply Fan
DP = Discharge Plenum
CO = Condenser Section
84.00
CLEAR
FORM 100.50-NOM6 (1207)
BOTH SIDES
60.00 CLEAR
FOR AIR INTAKE
136.82
REAR VIEW
6.28
38.37
170.31
195.38
221.00
339.00
GAS LINE CONNECTION
2-1/2" GAS OUTLET
1-1/2" MPT CONN.
GAS HEAT FLUE
ELECTRICAL SERVICE
69.83
75.58
5.74
OA OA
191.19
230.62
TOP VIEW
49.94 4.79
1-1/4" FPT DRAIN
1.50
106.00
LEFT SIDE ONLY
AIRFLOW
GAS
BURNERS
120.00 CLEAR
91.00
CLEAR
PULL
FOR COIL
SIDE VIEW
(LEFT SIDE)
NOTES:
1. 10’ clearance minimal over the top of the condensing unit.
2. Only one adjacent wall can exceed unit height.
3. 12’ clearance required to adjacent units.
4. 8’ service access recommended on one side.
5. Economizer and exhaust hoods, where applicable are folded inside unit for shipment.
FIG. 2-4 – GENERAL ARRANGEMENT DRAWING (CONT.)
26
GAS HEAT EXHAUST FLUE
FIELD INSTALLED
82.00
95.25
92.00
102.62
FRONT VIEW
30.00
BOTH
ANCE
DOOR
SIDES
SWING
CLEAR-
78.00 CLEAR
FOR COIL PULL
LD08370
JOHNSON CONTROLS
GENERAL ARRANGEMENT DRAWINGS (CONTINUED)
BOTTOM SUPPLY / REAR RETURN
SECTION DESCRIPTIONS:
EE = Economizer
FE = Fan Exhaust
_F = Filter Segments
CC = Cooling Coils
FS = Supply Fan
DP = Discharge Plenum
CO = Condenser Section
84.00
CLEAR
FORM 100.50-NOM6 (1207)
BOTH SIDES
60.00 CLEAR
FOR AIR INTAKE
6.36
36.28
76.48
136.82
REAR VIEW
7.76
2
339.00
170.31
11.00
106.00
1-1/4" FPT
DRAINS
BOTH SIDES
1.50
46.0060.00
39.00
195.00
227.25
SIDE VIEW
(LEFT SIDE)
AIRFLOW
OA
ELECTRICAL SERVICE
OA
EE
FS CC
FE
_F
TOP VIEW
DP
120.00 CLEAR
91.00
PULL
CLEAR
FOR COIL
CO
66.00
NOTES:
1. 10’ clearance minimal over the top of the condensing unit.
2. Only one adjacent wall can exceed unit height.
3. 12’ clearance required to adjacent units.
4. 8’ service access recommended on one side.
5. Economizer and exhaust hoods, where applicable are folded inside unit for shipment.
FIG. 2-4 – GENERAL ARRANGEMENT DRAWING (CONT.)
JOHNSON CONTROLS
82.00
92.00
100.50
SWING
30.00 DOOR
FRONT VIEW
BOTH SIDES
CLEARANCE
78.00 CLEAR
FOR COIL PULL
LD08296
27
Installation
CURB LAYOUT DRAWING / 050-061 MODELS
FORM 100.50-NOM6 (1207)
333.69
71.83
41.19
66.08
SUPPLY
229.56
35.10
21.00
66.19
RETURN
LD08297
84.50
14.00
1.75
TYP
NOTES:
1. Unit must be installed square and level.
2. Curb confi guration for “bottom” return and “bottom” supply.
3, These drawings are not intended as construction documents for the fi eld fabricated roof curbs. Johnson Controls will not be responsible for
the unit fi t up, leak integrity, or sound level for installation using fi eld fabricated roof curbs.
4. The YPAL unit does not have a base pan under the condensing section of the unit. Field fabricated roof curbs must have a cap on the top of
the condensing section of the curb to prevent moisture from entering the space. The cap design must be sloped away from the supply duct
opening to the end of the unit for the drainage of the moisture off of the top of the cap.
FIG. 2-5 – GENERAL ARRANGEMENT DRAWING
28
JOHNSON CONTROLS
ELECTRICAL SERVICE SIZING
FORM 100.50-NOM6 (1207)
ELECTRICAL DATA
In order to use the electrical service required for
the cooling only eco2 rooftop, use the appropriate
calculations listed below from U.L. 1995. Based on the
confi guration of the rooftop, the calculations will yield
different MCA (minimum circuit ampacity), and MOP
(maximum overcurrent protection).
Using the following load defi nitions and calculations,
determine the correct electrical sizing for your unit. All
concurrent load conditions must be considered in the
calculations, and you must use the highest value for any
combination of loads.
Load Defi nitions:
• LOAD1 is the current of the largest motor – compressor or fan motor.
• LOAD2 is the sum of the remaining motor currents that may run concurrently with LOAD1.
TABLE 2-7 – COMPRESSOR DATA - R410A
MODEL MODEL
1A ZP120 33.3 239 17.9 125 12.8 80
050
051
060
061
1B ZP137 48.0 245 18.6 125 14.7 100
2A ZP121 33.3 239 17.9 125 12.8 80
2B ZP137 48.0 245 18.6 125 14.7 100
1A ZP137 48.0 245 18.6 125 14.7 100
1B ZP137 48.0 245 18.6 125 14.7 100
2A ZP137 48.0 245 18.6 125 14.7 100
2B ZP137 48.0 245 18.6 125 14.7 100
1A ZP137 48.0 245 18.6 125 14.7 100
1B ZP182 55.7 340 26.9 172 23.7 132
2A ZP137 48.0 245 18.6 125 14.7 100
2B ZP182 55.7 340 26.9 172 23.7 132
1A ZP154 51.3 300 22.4 150 19.8 109
1B ZP182 55.7 340 25.0 172 23.7 132
2A ZP137 48.0 245 18.6 125 14.7 100
2B ZP182 55.7 340 25.0 172 23.7 132
208-230/3/60 460/3/60 575/3/60
RLA* LRA RLA* LRA RLA* LRA
• LOAD3 is the current of the electric heaters
– zero for cooling only units.
• LOAD4 is the sum of any remaining currents
greater than or equal to 1.0 amp.
Use the following calculations to determine MCA
and MOP for units supplied with a single-point power
connection:
MCA = (1.25 x LOAD1) + LOAD2 + LOAD3 + LOAD4
MOP = (2.25 x LOAD1) + LOAD2 + LOAD3 + LOAD4
If the MOP does not equal a standard current rating
of an overcurrent protective device, then the marked
maximum rating is to be the next lower standard rating.
However, if the device selected for MOP is less than the
MCA, then select the lowest standard maximum fuse
size greater than or equal to the MCA.
NOMINAL VOLTAGE
2
TABLE 2-8 – POWER SUPPLY VOLTAGE LIMITS
POWER SUPPLY MINIMUM VOLTAGE MAXIMUM VOLTAGE
208/230V/3PH/60HZ 187 253
460V/3PH/60HZ 414 506
575V/3PH/60HZ 518 632
JOHNSON CONTROLS
29
Installation
FORM 100.50-NOM6 (1207)
ELECTRIC DATA (CONTINUED)
TABLE 2-9 – SUPPLY AND EXHAUST FAN MOTOR DATA - ODP
HIGH EFFICIENCY PREMIUM EFFICIENCY
MOTOR
HP
5 14.0 13.8 8.3 6.9 5.3 5 13.8 13.2 6.6 5.2
7.5 21.7 20.0 13.3 10.0 8.2 7.5 20.0 19.4 9.7 7.4
10 28.2 26.0 17.5 13.0 11.0 10 26.0 25.0 12.5 10.3
15 41.0 38.0 24.5 19.0 16.2 15 37.4 35.4 17.7 14.1
20 53.0 48.0 32.0 24.0 19.8 20 49.4 47.0 23.5 18.9
25 66.0 62.0 39.0 31.0 23.8 25 63.3 60.0 30.0 24.2
30 84.0 72.0 46.0 36.0 29.0 30 74.1 70.0 35.0 28.0
40 106.0 98.0 59.0 49.0 38.8 40 97.5 92.0 46.0 37.4
208/3/60 230/3/60 380/3/60 460/3/60 575/3/60 208/3/60 230/3/60 460/3/60 575/3/60
FLA FLA FLA FLA FLA FLA FLA FLA FLA
NOMINAL VOLTAGE
MOTOR
HP
TABLE 2-10 – SUPPLY AND EXHAUST FAN MOTOR DATA - TEFC
HIGH EFFICIENCY PREMIUM EFFICIENCY
MOTOR
HP
5 15.4 14.2 8.1 7.1 5.4 5 13.6 13.0 6.5 5.2
7.5 21.2 19.6 12.0 9.8 8.2 7.5 21.0 18.8 9.4 8.0
10 27.5 25.6 16.8 12.8 11.4 10 26.0 25.0 12.5 10.0
15 40.0 37.0 23.8 18.5 15.3 15 38.9 37.0 18.5 14.8
20 54.0 50.0 30.0 25.0 19.1 20 51.0 48.0 24.0 19.0
25 64.0 60.0 39.0 30.0 25.0 25 63.3 60.0 30.0 23.9
30 78.0 72.0 46.0 36.0 29.6 30 77.0 72.0 36.0 29.0
40 101.0 94.0 57.0 47.0 38.0 40 99.0 92.0 46.0 36.8
208/3/60 230/3/60 380/3/60 460/3/60 575/3/60 208/3/60 230/3/60 460/3/60 575/3/60
FLA FLA FLA FLA FLA FLA FLA FLA FLA
NOMINAL VOLTAGE
MOTOR
HP
NOMINAL VOLTAGE
NOMINAL VOLTAGE
TABLE 2-11 – CONDENSER FAN MOTOR RLA - STANDARD FAN
RLA EACH MOTOR
MODEL
50-61 TONS 4 29.2 24.8 12.4 10.0
QUANTITY OF
FANS
208V/3PH/60HZ 230V/3PH/60HZ 460V/3PH/60HZ 575V/3PH/60HZ
7.3 6.2 3.1 2.5
208V/3PH/60HZ 230V/3PH/60HZ 460V/3PH/60HZ 575V/3PH/60HZ
TABLE 2-12 – CONDENSER FAN MOTOR RLA - LOW SOUND FAN (FUTURE OPTION)
RLA EACH MOTOR
MODEL
50-61 TONS 4 32.4 27.6 13.6 12.0
QUANTITY OF
FANS
208V/3PH/60HZ 230V/3PH/60HZ 460V/3PH/60HZ 575V/3PH/60HZ
7.3 6.2 3.1 2.5
208V/3PH/60HZ 230V/3PH/60HZ 460V/3PH/60HZ 575V/3PH/60HZ
TABLE 2-13 – MISCELLANEOUS ELECTRICAL DATA
NOMINAL VOLTAGE
DESCRIPTION
CONTRL X’FMR. 500 VA 2.4 1.1 0.9 2
CONVENIENCE OUTLET 9.6 4.4 3.5 N/A
GAS HEAT 9.6 4.4 3.5 5.3
208 / 230V 460V 575V 380V-60
AMPS AMPS AMPS AMPS
30
JOHNSON CONTROLS
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